Waste identification and water utilization in the thread dyeing industry: An improvement strategy for long-term development

Abstract

Fierce competition in the textile sector forces one to make a production system more efficient and increase productivity by reducing total throughput time using the Lean manufacturing system. These two objectives can be achieved through Value Stream Mapping (VSM) and process modifications. Water usage is the textile industry's major environmental concern, but little research has been done on how to effectively manage water at the process level by identifying the crucial variables impacting the dyeing water consumption rate. This research targets these objectives in a Textile Dyeing company in Gazipur. Bangladesh's textile thread dyeing industry has a substantial impact on the national economy. Dyeing can be utilized at several phases of the textile-making process. Color is a crucial aspect of the appeal, regardless of how excellent a fabric's construction is. By reducing wastes that are identified at various stages of dyeing thread, the entire process can become more effective and efficient. Utilizing water wisely in the thread dyeing industry may result in a large decrease in water use, ensuring environmental sustainability. This research has been conducted at a reputed sewing thread manufacturing plant to explore the possibility of minimizing water use in the thread dyeing process without hampering the fabric quality and to identify any potential waste generated during the entire process. Non-value-adding activities have been identified for removal, some processes have been streamlined and some processes have been modified. Value stream mapping (VSM), a lean method that uses a flowchart to describe each stage in the production process, was applied to the 34-kilogram batch (the batch that is run the most) to find waste, shorten process cycle times, and implement process improvement. It is possible to gain a broad grasp of what is happening in the production system from this VSM, as opposed to what ought to or might occur. This helps to focus on the few most important reasons for the seven categories of waste it generates and eliminates. The "Radio Frequency Drying" and "Winding" procedures are identified as potential areas for improvement in this VSM, as their inventory and lead time are quite high. According to evaluations of the thread dyeing processing data gathered, there are a variety of variables that affect water consumption, including capacity utilization, product mix, shade depth, First Time Right (FTR), machine wash, and the adoption of new technologies or processes. These changes have a significant impact on productivity improvement.